Project Cheapo Muffler..Zap spin off

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So there is no way I am paying 600.00 for a Ford Factory exh. system as my muffler is rotted out. The pipes are fine just the muffler is gone. I also looked at the walker pipes and they are thin junk. The factory pipes are sort of mandrel bent and real thick material. I priced a walker replacement muffler 18887 and was quoted from 110.00 to 130.00 at 2 different parts stores. My buddy owns one of them. Go figure. Anyway got the same one at rockauto.com for 63.00 plus a few bucks shipping. Cut apart the pipes today and had to add a little bit to each end. I had that material laying around. Took about 3 hours. I still saved money.www.tjsperformance.comDynasty 300 DXHTP 240HTP Microcut 380Hyperthem 85JD2 Hyd Bender and HF Hyd Ring Roller all in one =(Frankenbender)Bpt. Mill/DRO4' x 8' CNC Plasma TableInstagram: tjsperformanceYT: TJS Welding and Fabrication
Reply:Bravo!It's NICE to be able to do stuff like this when you have to with reasonable amount of effort involved..And the right tools.....zap!I am not completely insane..Some parts are missing Professional Driver on a closed course....Do not attempt.Just because I'm a  dumbass don't mean that you can be too.So DON'T try any of this **** l do at home.
Reply:Good job. I did my wife's car a month or so ago. I had previously sent my wife to the muffler shop to do it because I hate exhaust work. It rotted out and was time to be redone. Boy was I MAD  when I got under there and saw the butcher job. They had torched mounts and used ill-fitting mufflers. No wonder the wife was telling me it was rattling. Ordered up the new parts. Massaged them in and rebuilt the proper hangers then hung using factory rubber. Wife is happy, job was done right, and I saved some dough. I still hate doing exhaust work.
Reply:I've seen several cases where the muffler will rot out, but the pipes before it and after it were still solid.
Reply:Those look familiar.  Ford superduty pipes.  I reworked a set for my truck several years ago.  The tailpipe interfered with my una-goose brand gooseneck hitch (don't ever buy one of those FYI).  I had the good fortune to have a friend who worked in R&D at the place that made those exausts so instead of cutting up my stock system I just took it off and made another one from test pipes and pieces that he found ; ) .  I also put in a straight through muffler so I had to work on the input pipe as well since the factory input / outputs are offset.  While I was at it, I put in a banks down pipe.The really keen ford guys will notice that the old tailpipe has the flare cut end because it was a 7.3 liter but the new pipes were from 6.0 liter model years so the end of the pipe is straight cut.  I cut a flare on that pipe before i installed it so it would still appear all stock. Attached ImagesLast edited by Chuck; 02-27-2012 at 04:27 PM.Miller 250x & Lincoln V205-TSmith Oxy-Prop torch
Reply:I can't do this, since valequez muffler is close to the house they will replace your muffler and weld it in for $60-$80. They did it on my girlfriends cavalier last year, cut off the old one, welded on the new one, and added a hanger all for $70 and in a matter of 20min. Can't beat that.You work looks great though.Torchmate 2x2 CNC with Flashcut CNC controlsHypertherm Powermax45 Esab ET220i Razorweld 195 MigRazorweld 200ac/dc TigTormach 770, Tormach xstechRazorweld, Vipercut/Vipermig, SSC Foot Pedal Dealer
Reply:Are majority of the exhaust pipes made out of Stainless steel?  I need to cut off my aftermarket exhaust and install my factory one back in, but it requires welding.
Reply:I do all my exhaust work I build the headers back minus the mufflers... My Impala has dual 4" exhaust on it... I just finished putting the tail pipes on it...Sounds Nice!  http://s595.photobucket.com/albums/t...12_231641Z.mp4
Reply:Originally Posted by krouchchocolateAre majority of the exhaust pipes made out of Stainless steel?  I need to cut off my aftermarket exhaust and install my factory one back in, but it requires welding.
Reply:I don't remember the exact year, but somewhere around 95 or so the EPA made it manditory that the factory exhaust systems on a vehicle had to last X number of years, or so many miles....not sure which, but that is when stainless exhaust systems became the norm on vehicles.  Most use 409 stainless, which in my experience welds really nice.Miller 250x & Lincoln V205-TSmith Oxy-Prop torch
Reply:Its a super Low grade of stainless.  I forget the actual grade but its the min amount of chromium to be considered stainless.Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:Originally Posted by DualieIts a super Low grade of stainless.  I forget the actual grade but its the min amount of chromium to be considered stainless.
Reply:409 is what most stainless exhaust is made of, it will form a "rust" like layer that actually prevents further corrosion of the pipe.
Reply:I took my 82 Chevy to a local guy here that everybody raves about. I had a 6.2L diesel in it and had swapped in a 454BB. I drove it down there real light on the throttle with just the headers on. It was cool. But he guy ruined my fender on his lift. Then charged me the difference on the check, but said he "took off" for the fender damage. It is a crap job. I started it up and could hear the joints hissing. I made him weld it all up until the hisses were gone. He charged me like 700bucks. I think I will never go down that road again. Two glasspacks and two Flowmaster 50 series and some aluminized exhaust pipe. If I had a bender for that stuff I would re work the whole thing. So i say you did an awesome job and better than professional.Lincoln Power Mig 210MP MIGLincoln Power Mig 350MP - MIG and Push-PullLincoln TIG 300-300Lincoln Hobby-Weld 110v  Thanks JLAMESCK TIG TORCH, gas diffuser, pyrex cupThermal Dynamics Cutmaster 101My brain
Reply:Jmink, is that a 69 camaro in one of your pics?
Reply:I just had a new universal cat put into my wife's VW, parts cost = $67. + $27 for the flex pipe.Dealer cost = $900+ESAB Heliarc 252
Reply:feel lucky here in CA they are now mandating ONLY OEM cat converters,  No aftermarket converters no matter if they pass smog or not.Vantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.
Reply:Originally Posted by Dualiefeel lucky here in CA they are now mandating ONLY OEM cat converters,  No aftermarket converters no matter if they pass smog or not.
Reply:Originally Posted by Dualiefeel lucky here in CA they are now mandating ONLY OEM cat converters,  No aftermarket converters no matter if they pass smog or not.
Reply:AH i forgot the fine print that the vehicle i had that needed them didnt have an verified cat con.   89 GMC 3500 7.4LVantage 500's LN-25's, VI-400's, cobramatics, Miller migs, synch 350 LX, Powcon inverters, XMT's, 250 Ton Acurrpress 12' brake, 1/4" 10' Atlantic shear,Koikie plasma table W/ esab plasmas. marvel & hyd-mech saws, pirrana & metal muncher punches.